Structural wall framework

ABSTRACT

A building framework is disclosed which comprises studs coupled together by separate bracing elements. The studs and bracing elements form a bracing unit. The bracing unit is provided between a top plate and bottom plate of the framework. The bracing elements extend substantially all of the way from the top plate to the bottom plate.

FIELD OF THE INVENTION

This invention relates to a structural wall framework, to a method offorming the framework and to a bracing unit for use in the framework.

BACKGROUND OF THE INVENTION

Prefabricated wall frameworks for buildings such as houses are made byadvancing a top plate and bottom plate past a fastening station. Studsare located between the plates and are fixed in place by a nailing orpressing machine or the like.

As is well known, studs are arranged at predetermined spacings such asabout 450 to 600 mm in order support loads which the framework will besubjected to when installed in a building. The studs are also requiredat these spacings to support plasterboard which will form the internalwall surface of the building.

In order to ensure that the framework has the required structuralintegrity, the framework is braced by bracing. The bracing can take anumber of forms, including angle brace, plywood brace and wooden brace.Generally the angle brace and wood brace needs to be cut into theframework, thereby reducing its strength, as the framework is beingprefabricated, and this greatly increases the time taken to form theframework and also the complexity of the manufacturing process. Plywoodbraces are usually only suitable for external walls or where brickveneer cladding is used.

Modern building designs and, in particular, domestic dwellings generallyinclude large window spaces. The incorporation of large window spaces inthe framework limits the amount of bracing which can be used, andtherefore the raking strength of the framework. The raking strength ofthe framework is the ability of the framework to restrain horizontalshear forces which apply a load which tends to flatten the frameworkgenerally in the plane of the framework. The effectiveness of the commonforms of wall bracing diminishes significantly as the length of thebraced section of the wall frame diminishes.

SUMMARY OF THE INVENTION

Among the objects of a first aspect of the invention is to provide astructural wall framework which can provide for large window spacings,yet still have sufficient raking strength to support required loads.

This aspect of the invention may be said to reside in a structural wallframework comprising a top plate, a bottom plate, and a plurality ofstuds extending between the top plate and the bottom plate. The studshave a first face and a second opposite face which are parallel to theplane of the wall framework. Side faces join the first and second faces.At least one bracing unit is connected to the top plate and bottomplate, and comprised of at least two of said studs and separate bracingelements interconnecting the studs. Each of the separate elements areconnected to the first or second faces of the at least two studs. Thebracing elements extend substantially all of the way from the top plateto the bottom plate.

By providing the plurality of bracing elements which are connected tothe studs and extend between the top plate and bottom plate, theframework is provided with the required raking strength in a smallerspace than with conventional angle brace and wooden brace. This allowslarge window spaces to be formed in the framework whilst at the sametime providing the required raking strength.

The use of a prefabricated bracing unit reduces the complexity ofmanufacture of the framework because studs together with suitablebracing can be concurrently provided in the framework. Thus, it is notnecessary to perform a separate step of cutting in angle brace or woodbrace into the framework. Thus, both the time taken to produce theframework and the complexity of the manufacturing process can bereduced.

A further aspect of the invention may be said to reside in a bracingunit for a structural wall framework. The bracing unit comprises atleast two spaced apart studs, each having a first face and a second facewhich are parallel. Side faces join the first and second faces. Thestuds have first and second ends. A plurality of separate bracingelements are connected to the first face or second face of the studs andextend substantially all the way from the first end to the second end ofthe studs.

A further aspect of the invention relates to a method of forming astructural wall framework. This aspect of the invention comprisesproviding a top plate and a bottom plate, and locating at least oneprefabricated bracing unit between the top plate and the bottom plate.The bracing unit comprises at least two studs each having ends, thestuds having a first face and a second face which are parallel to aplane of the wall framework and side faces joining the first and secondfaces, and a plurality of separate bracing elements extendingsubstantially all of the way from one end of the bracing unit to theother end of the bracing unit. The bracing unit is connected to the topplate and bottom plate.

Thus, according to this aspect of the invention, both bracing and studsare incorporated into the framework in a single operation, therebydecreasing the amount of work which is required to form the framework,and also simplifying the manufacturing process.

Other objects and features of the present invention will be in partapparent and in part pointed out hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will be described, by way ofexample, with reference to the accompanying drawings, in which:

FIG. 1 is a view of a bracing unit according to one embodiment of theinvention;

FIG. 2 is a view of a bracing unit according to a second embodiment ofthe invention;

FIG. 3 is a view of a bracing element according to the preferredembodiment of the invention;

FIG. 4 is a view of a structural wall framework according to oneembodiment of the invention;

FIG. 5 is a detailed view showing connection of a bracing unit to abottom plate of the framework; and

FIG. 6 is a view along the line V-V of FIG. 5.

Corresponding reference characters indicate corresponding partsthroughout the views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 shows a bracing unit 10 according to one embodiment of theinvention. The bracing unit 10 comprises spaced apart studs 12 and 14which have free ends 13 and which are connected together by a bracingsystem 15 which comprises discrete bracing elements 16 and 17.

In the preferred embodiment of the invention, the elements 16 comprisemetal braces sold under the registered trade mark POSI-STRUTmanufactured by MiTek. The bracing element 17 comprises one half of abracing element 16. As is shown in FIG. 3 the bracing element 16 has aweakening 32 formed by partially cutting or scoring the element 16 sothe element 16 can be easily broken in half to form the two elements 17.The bracing elements 16 and 17 are provided with punched teeth 31 (seeFIG. 3) at end plate regions 18 which penetrate into the studs 12 and 14to thereby fix the bracing elements 16 and 17 to the studs 12 and 14 toform the bracing unit 10.

The bracing elements which are connected to the studs may comprise onlybracing elements 16, only bracing elements 17, or as is shown in thedrawings, a combination of the elements 16 and 17. By using elements 16and 17 it is more easy to provide an integral number of bracing elementswhich extend all of the way from one end of the studs to the other endof the studs with suitable small spacings between the elements toprovide as many bracing elements as is possible from the bracingelements 16 and 17 to thereby increase the raking strength of theframework including the bracing unit.

In other embodiments, bracing elements of a different type to thoseformed by or of the POSI-STRUT braces referred to above could be used.These include thin strips of metal, wooden elements such as rectangularcross-section boards. Furthermore, the shape of the elements may bedifferent to those referred to above. Still further, the elements neednot extend between the studs at acute angles (about 45 degrees as in thepreferred embodiment), but could extend at other angles includingperpendicular (i.e. horizontally) to the studs.

The vertical height of the units 10 depend on the size of the wall framewhich is being made, and the height of the units 10 may be anywherebetween, for example, 2100 mm to 2700 mm. The studs 12 and 14 may bespaced apart by a distance between 300 and 400 mm for example. Thebracing elements 16 and 17 extend substantially the full length of thestuds 12 and 14 between free ends 13 of the studs so that when the unit10 is arranged vertically, the bracing elements 16 and 17 extend all theway from an upper end of the bracing unit 10 to a lower end of thebracing unit 10. The elements 16 and 17 are spaced apart, as is requiredto enable a number of the bracing units 16 or 17 to be so located.

The formation of the bracing system 15 from the discrete bracingelements 16 or 17 accommodates a greater variation in height of theframe unit by simply increasing the size of the gaps between elements16, 17 as is needed to ensure that an integral number of the units areprovided to extend between the top end and lower end of the bracing unit10.

A nogging 19 may be provided between the studs 12 and 14 as is shown.

FIG. 2 shows a second embodiment in which a bracing unit 20 is comprisedof three studs 22, 24 and 26. As in the previous embodiment, a bracingsystem 25 is provided which extends from the upper end of the bracingunit 20 to the bottom end of the bracing unit 20. The bracing system 25comprises two sets 25′ and 25‘’ of discrete bracing elements 16 and 17which are the same as those described with reference to FIG. 1. Onceagain, the bracing elements 16 and 17 are spaced apart to extend all ofthe way between the free ends 13 of the studs 22, 24 and 26.

As in the earlier embodiment, noggings 19 may be provided betweenadjacent studs 22, 24 and 26.

In other embodiments, the bracing unit may include four or more studswith appropriate numbers of bracing sets interconnecting the adjacentstuds.

It should also be understood in other embodiments the bracing elementsmay have a different configuration to those shown in the drawings.Whilst in the embodiment of FIG. 2 the two sets of bracing elements arehorizontally aligned, the horizontal configuration is optional and thetwo sets of bracing elements could be staggered with respect to oneanother.

The embodiment of FIG. 2 provides a stronger wall frame than theembodiment of FIG. 1. Although the effective length L of the bracingunit of FIG. 2 is double the length L of the bracing unit of FIG. 1 theconfiguration of FIG. 2 gives more than double the strength. Thus, theembodiment of FIG. 2 provides more than double the raking strengthcompared to the embodiment of FIG. 1 while still using relatively smallcomponents which are also used in the embodiment of FIG. 1.

The embodiments of FIGS. 1 and 2 greatly increase the horizontal rakingload a wall frame using the bracing units can take, compared to anequivalent width of a braced framework according to conventional bracingtechniques. Typically, conventional systems for bracing adjacent studshave a single brace extending between a top of one stud to a bottom ofthe adjacent stud. When studs must be spaced relatively closer together,the brace tends to become more nearly vertical. That leaves the bracepractically ineffective in resisting the horizontal loads. This is notthe case in the present invention which features multiple unit braceswhich remain more nearly horizontal.

Typically the load which the bracing unit of FIG. 2 can take is in theorder of 2.7 kN and the length L of the bracing unit is in the order of750 mm. This compares to a conventional braced wall frame using angleiron or timber bracing which would require bracing of a length of inorder of 1800 mm in order to provide the same capacity. Thus, in thisembodiment of the invention, the load capacity is provided by a greatlyreduced length L compared to conventional systems, thereby increasingthe amount of space which is available for a window without sacrificingraking strength.

FIG. 4 is a view of a framework 50 according to one embodiment of theinvention. The framework 50 has a top plate 51 and a bottom plate 52.For illustrative purposes, the bracing unit 10 described with referenceto FIG. 1 is located at one end of the framework 50 and the bracing unit20 described with reference to FIG. 2 is located at the other end.However, it should be understood that the wall framework may includeonly bracing units according to the embodiment of FIG. 1, or onlybracing units according to the embodiment of FIG. 2, or some othercombination of those two types of bracing units. A window space 30 isdefined between the bracing units 10 and 20 and the top plate 51 andbottom plate 52. The framework 50 is formed by locating the bracing unit10 between the plates 52, so the free ends 13 of the studs abutrespective plates 51 and 52 and securing the framework 10 to the plates51 and 52 by fasteners, as will be described with reference to FIGS. 5and 6. Similarly, the bracing unit 20 is located at the other end of theplates 51 and 52 and secured in place.

The bottom plate 52 may be provided with tie down connectors 60 tofacilitate connection of the framework to a floor frame or concrete slabof a building.

In the preferred embodiment of the invention, the bracing elementsformed from the POSI-STRUT braces are thin and are connected on a firstface 21 of the studs 12 so that the opposite second face 23 of the studsare left completely free, thereby providing a surface for location ofplasterboard which is not interfered with by bracing or the like. Thefirst face 21 and second face 23 of the studs are joined by side faces27. The first face 21 of the studs is the side of the studs which isintent to be outermost when the framework is installed in a building.Thus, the bracing on first face 21 of the studs is substantially flushwith the studs and is easily accommodated within the brick cavity of anexterior building wall.

The framework of the present invention therefore particularly lendsitself to exterior walls of a building in which window spaces arerequired. However, the framework could be used as an internal wall of abuilding if required.

The framework shown in FIG. 4 may also include individual studs 29 whichare connected to the top plates 51 and 52 in the usual manner.Typically, a number of such conventional studs 29 are connected in thenormal manufacturing technique by advancing the top plate 51 and bottomplate 52 past a securing station and locating the stud or studs 29 inplace, and then securing them to the top plate 51 and bottom plate 52.

After the standalone studs 29 have been connected in place, the bracingunits 10 and 20 can be lifted into position and then secured to the topplate 51 and bottom plate 52.

FIGS. 5 and 6 show one method of connecting the studs of the bracingunits 10 and 20 to the top plate 51 and bottom plate 52. The stand alonestuds 29 can be connected in the same manner.

As is shown in FIGS. 5 and 6, the studs 12 and 14 are connected tobottom plate 52 by a generally U-shaped strap 90 which has an arm 91 andopposite arm 92 and a base 93. The arms 91 and 92 may be provided withpunched teeth for penetrating the stud 12 and bottom plate 52, or may beprovided with holes so that the arms 91 and 92 can be nailed to the stud12 such as by nails 33.

The other ends of the studs 12 and 14 are connected to the top plate 51(not shown in FIGS. 5 and 6) in the same manner.

Thus, the studs 12 and 14 are connected to the plates 51 and 52 in thesame manner as individual studs would have been connected in theconventional manufacturing method. However, in this embodiment of theinvention, bracing is concurrently incorporated into the framework whenthe studs 12 and 14 are secured to the plates 51 and 52. Thus, in thepreferred embodiment of the invention the bracing elements 16 and 17 areconnected to the studs 12 and 14, and 22, 24 and 26 before the bracingunits 10 and 20 are attached to the top plate 51 and bottom plate 52.Therefore the bracing is provided at the same time as those studs.However, in other embodiments the bracing elements 16 and 17 could beattached on site after the studs 12 and 14, and 22, 24 and 26 areconnected to the top plates 51 and 52.

In the preferred embodiment shown in FIGS. 1 and 2 the ends of the studs12 and 14, 22, 24 and 26 connect directly to the top plate 51 and bottomplate 52. However, in other embodiments cross members (not shown) may beprovided at the ends 13 of the studs and the cross members may connectto the top plate 51 and bottom plate 52.

In the claims which follow and in the preceding description of theinvention, except where the context requires otherwise due to expresslanguage or necessary implication, the word “comprise”, or variationssuch as comprises” or “comprising”, is used in an inclusive sense, i.e.to specify the presence of the stated features but not to preclude thepresence or addition of further features in various embodiments of theinvention.

Since modifications within the spirit and scope of the invention mayreadily be effected by persons skilled within the art, it is to beunderstood that this invention is not limited to the particularembodiment described by way of example hereinabove.

1. A structural wall framework comprising: a top plate; a bottom plate;a plurality of studs extending between the top plate and the bottomplate, the studs having a first face and a second opposite face whichare parallel to the plane of the wall framework, and side faces joiningthe first and second faces; and at least one bracing unit connected tothe top plate and bottom plate, and comprised of at least two of saidstuds and separate bracing elements interconnecting the studs, each ofthe separate elements being connected to the first or second faces ofthe at least two studs, and the bracing elements extending substantiallyall of the way from the top plate to the bottom plate.
 2. The frameworkof claim 1 wherein the bracing unit comprises two studs and the saidbracing elements.
 3. The framework of claim 1 wherein the bracing unitcomprises three studs.
 4. The framework of claim 3 wherein two sets ofseparate bracing elements are connected to the studs, a first of the twosets of bracing elements extending between a first outer stud of thethree studs and an intermediate stud of the three studs, and the secondset of separate bracing elements extending between the said intermediatestud and a second outer stud of the three studs.
 5. The framework ofclaim 3 wherein the bracing elements have punched teeth for connectingthe bracing elements to the respective studs.
 6. The framework of claim1 wherein the bracing unit also includes at least one nogging extendingbetween adjacent studs.
 7. The framework of claim 1 wherein each studhas a first end and a second end, the first end contacting the top plateand the second end contacting the bottom plate.
 8. The framework ofclaim 1 wherein the bracing unit is a prefabricated bracing unitcomprised of at least two studs and the said separate bracing elements.9. A bracing unit for a structural wall framework, the bracing unitcomprising: at least two spaced apart studs, each having a first faceand a second face which are parallel, side faces joining the first andsecond faces, and the studs having a first end and a second end; and aplurality of separate bracing elements connected to the first face orsecond face of the studs and extending substantially all the way fromthe first end to the second end of the studs.
 10. The bracing unit ofclaim 9 wherein the unit comprises two studs and the said bracingelements.
 11. The bracing unit of claim 9 wherein the bracing unitcomprises three studs comprised of a first outer stud, an intermediatestud, and a second outer stud, and a first set of said separate bracingelements connected to the first stud and the intermediate stud, and asecond set of said separate bracing elements connected to theintermediate stud and the second stud.
 12. The bracing unit of claim 9wherein the bracing unit includes at least one nogging located betweenadjacent said studs of the bracing unit.
 13. The bracing unit of claim 9wherein the bracing elements have punched teeth for connecting thebracing elements to the respective studs.
 14. The bracing unit of claim9 wherein the separate bracing elements are all connected to the firstface of the studs.
 15. The bracing unit of claim 9 wherein the separatebracing elements are spaced apart from one another so that apredetermined number of the bracing elements extend between the firstend and second opposite end of the studs.
 16. A method of forming astructural wall framework, comprising: providing a top plate and abottom plate; locating at least one prefabricated bracing unit betweenthe top plate and the bottom plate, the bracing unit comprising at leasttwo studs each having ends, the studs having a first face and a secondface which are parallel to a plane of the wall framework, and side facesjoining the inner and outer faces, and a plurality of separate bracingelements extending substantially all of the way from one end of thebracing unit to the other end of the bracing unit; and connecting thebracing unit to the top plate and bottom plate.
 17. The method of claim16 wherein the prefabricated bracing unit comprises two said studs andthe said bracing elements.
 18. The method of claim 16 wherein theprefabricated bracing unit comprises three studs and two sets ofseparate bracing elements, a first of the two sets of bracing elementsextending between a first outer stud of the three studs and anintermediate stud of the three studs, and the second set of bracingelements extending between the said intermediate stud and a second outerstud of the three studs.
 19. The method of claim 16 wherein the bracingelements have a plurality of punched teeth for connecting the bracingelements to the studs.
 20. The method of claim 16 wherein theprefabricated bracing unit also includes at least one nogging extendingbetween adjacent studs.